The growing use of high-voltage electrical systems and faster charging technologies in electric vehicles is placing greater demands on engineering plastics, particularly those used around battery packs.
For material suppliers, one of the challenges is developing polymers that can withstand extreme temperatures without losing their structural integrity.
At the Autocar Professional India EV Conclave 2026, Anton Kumanan, Technology Leader – India, Ascend Performance Materials, discussed the company’s work on advanced polyamides, including materials designed to retain their properties during short periods of exposure to high temperatures.
Cross-Linking to Improve Thermal Resistance
Conventional polyamide 66 begins losing stiffness as temperatures approach its melting range of approximately 240–260 degrees Celsius. According to Anton, cross-linking changes the behaviour of the material, allowing it to retain structural integrity at temperatures where conventional polyamides would lose their mechanical properties.
The process involves moulding the polymer using conventional injection-moulding equipment, followed by an additional electron-beam treatment. This creates cross-links within the material, improving its ability to withstand elevated temperatures.
“It nearly becomes a thermoset,” Anton said, explaining how the electron-beam treatment changes the polymer’s behaviour.
One application being explored is the protection of components surrounding EV battery packs during thermal runaway. Anton said the material’s ability to maintain structural integrity could provide occupants with additional time to escape.
He indicated that the technology could offer more than two minutes of additional protection, although the actual performance would depend on the extent of cross-linking, part design and the validation carried out for individual applications.
The electron-beam dosage determines the degree of cross-linking, making process control an important part of component development.
Applications Beyond Battery Protection
Ascend is working with global automotive manufacturers on applications involving overmoulded busbars, which require electrical insulation and resistance to elevated temperatures.
Anton said the material offers flame resistance while retaining colour stability at high temperatures. These characteristics are relevant to electrical components where material performance must be maintained under demanding operating conditions.
The company already has a portfolio of flame-retardant polyamides under Starflam which has more than 100 UL yellow cards, cross-linking provides an additional level of temperature resistance beyond conventional flame-retardant formulations.
He also pointed to potential applications in battery packs and other areas where higher charging rates could expose components to demanding thermal conditions. Attached an image of samples behaviour of standard FR PA66, Aluminium and X-Protect PA66 (Cross-linked) at same thickness after the exposure of direct flame at 1100˚C with 1.4 kW power
Localising the Manufacturing Process
Ascend entered India in 2022 through the acquisition of Chennai-based Formulated Polymers. The company operates a compounding facility in Chennai, which caters to customers across India with reinforced and flame-retardant formulations.
Anton said Ascend is looking to manufacture Starflam X-Protect i.e. cross-linking technology in India. The manufacturing process would involve Tier 1 suppliers moulding the components, followed by electron-beam treatment at industrial facilities.
First, Ascend supplies a specially formulated, ready-to-use compound. Next, the Tier-1 moulder produces the required component using a conventional moulding process.
The moulded part then receives a controlled secondary treatment such as electron-beam irradiation to develop a crosslinked structure. Finally, the part need to be validated in its intended battery-system environment with OEM’s support.
According to him, the required cross-linking infrastructure is already available in India in Industrial scale and Ascend is working with some of them.
The company is also seeking collaboration with Indian OEMs and Tier 1 suppliers to identify critical applications that demand critical conditions in EV and undertake component development locally via collaborative efforts.
Specialty Polyamides for Dimensional Stability
Apart from cross-linked PA66, Anton discussed Ascend’s specialty polyamide 6 10 and 6 12 materials, i.e. HiDura grades which have lower moisture absorption than conventional PA6 and PA66.
Moisture absorption can affect the dimensional stability, strength and stiffness of nylon components. Anton said the lower absorption levels of PA610 and PA612 help maintain these properties, particularly in applications where dimensional consistency is important.
He also highlighted their resistance to chemicals, including automotive coolants and fuels. According to Anton, testing of certain materials showed property retention exceeding 50% after 1,000 hours of exposure.
Engineering Support in India
Ascend is also developing local engineering capabilities like CAE and Moldflow through its presence at IIT Madras Research Park, where it works with academic researchers and industry specialists.
Anton said the objective is to provide Indian customers with material engineering and application development support rather than operate solely as a polymer raw material supplier.
With technical teams in Chennai, Pune and Gurugram, the company is looking to work more closely with OEMs and component manufacturers on thermal management, lightweighting and high-temperature applications.
Anton invited automotive manufacturers and Tier 1 suppliers to collaborate on developing and validating these materials for Indian applications, including components intended for global vehicle programmes.